U.S. patent application number 13/837194 was filed with the patent office on 2013-08-08 for wet-end manufacturing process for bitumen-impregnated fiberboard.
This patent application is currently assigned to W. R. MEADOWS, INC.. The applicant listed for this patent is W.R. Meadows, Inc.. Invention is credited to Tariq Mahmood Malik.
Application Number | 20130202877 13/837194 |
Document ID | / |
Family ID | 41725913 |
Filed Date | 2013-08-08 |
United States Patent
Application |
20130202877 |
Kind Code |
A1 |
Malik; Tariq Mahmood |
August 8, 2013 |
Wet-End Manufacturing Process for Bitumen-Impregnated
Fiberboard
Abstract
A process for manufacturing fiberboard by preparing a fiber
slurry mixture including containing cellulose fibers and water then
atomizing a liquid bituminous material, such as asphalt. The liquid
bituminous material is atomized by mixing it with a pressurized
gas, such as compressed air, forming a mist comprising droplets of
bituminous material having a diameter between 20 microns and 50
microns. A water spray solidifies the bituminous material droplets
thereby forming bituminous particles which fall into the fiber
slurry within the spray chamber. From there the slurry is sheared,
dewatered, and dried, forming a finished fiberboard.
Inventors: |
Malik; Tariq Mahmood;
(Batavia, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
W.R. Meadows, Inc.; |
Hampshire |
IL |
US |
|
|
Assignee: |
W. R. MEADOWS, INC.
Hampshire
IL
|
Family ID: |
41725913 |
Appl. No.: |
13/837194 |
Filed: |
March 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13772931 |
Feb 21, 2013 |
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13837194 |
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13526177 |
Jun 18, 2012 |
8382951 |
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13772931 |
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13248758 |
Sep 29, 2011 |
8241463 |
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13526177 |
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12881721 |
Sep 14, 2010 |
8038845 |
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13248758 |
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12200993 |
Aug 29, 2008 |
7815772 |
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12881721 |
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Current U.S.
Class: |
428/323 ;
162/162; 162/171; 428/484.1; 428/489; 428/491 |
Current CPC
Class: |
Y10T 428/249924
20150401; Y10T 428/25 20150115; D21H 23/00 20130101; Y10T 428/31823
20150401; D21J 1/08 20130101; E01C 11/02 20130101; Y10T 428/31815
20150401; D21J 1/06 20130101; D21H 19/00 20130101; Y10T 428/31801
20150401; C08L 95/00 20130101; Y10T 428/31819 20150401; D21H 17/61
20130101 |
Class at
Publication: |
428/323 ;
162/171; 162/162; 428/489; 428/484.1; 428/491 |
International
Class: |
E01C 11/02 20060101
E01C011/02 |
Claims
1. A bitumen-impregnated fiberboard comprising: a core comprising
at least 10% weight bituminous material, cellulose fibers, one or
more filler materials; and an optional outer coating disposed on
both major sides of the fiberboard.
2. The bitumen-impregnated fiberboard of claim 1 wherein the core
further comprises from about 0.001% weight to about 10.0% weight
dye.
3. The bitumen-impregnated fiberboard of claim 1 wherein the
bituminous material is asphalt.
4. The bitumen-impregnated fiberboard of claim 1 wherein the filler
materials are selected from the group consisting of, but not
limited to, a wax, a starch, and an aluminum sulfate and/or sodium
aluminate.
5. The bitumen-impregnated fiberboard of claim 1 further comprising
about 0.1% weight to about 10.0% weight wax; about 0.1% weight to
about 10.0% weight starch; and about 0.1% weight to about 10.0%
weight aluminum sulfate.
6. The bitumen-impregnated fiberboard of claim 1 wherein the
coating is selected from the group consisting of, but not limited
to, asphalt, flux oil, and fuel oil.
7. The bitumen-impregnated fiberboard of claim 1 wherein the
bituminous material has a particle size of less than approximately
20 microns.
8. The bitumen-impregnated fiberboard of claim 1 wherein the
bituminous material has a particle size in the range of
approximately 20 to 50 microns.
9. The bitumen-impregnated fiberboard of claim 1 wherein the
bituminous material has a particle size of greater than
approximately 50 microns.
10. The fiberboard or expansion joint of claim 1, wherein the
fiberboard or expansion joint has a density of at least 19 lb/cu.
ft. or greater.
11. The fiberboard or expansion joint of claim 1, wherein the
fiberboard or expansion joint has a compression, as measured in
accordance with ASTM D 1751-04, of at least about 100 psi or
greater.
12. The fiberboard or expansion joint of claim 1, wherein the
fiberboard or expansion joint has an extrusion, as measured in
accordance with ASTM D 1751-04, of less than 0.30 inches.
13. The fiberboard or expansion joint of claim 1, wherein the
fiberboard or expansion joint has a recovery, as measured in
accordance with ASTM D 1751-04, of at least 70%.
14. The fiberboard or expansion joint of claim 1, wherein the
fiberboard or expansion joint has a water absorption, as measured
in accordance with ASTM D 1751-04, of 24 volume % or less.
15. The bitumen-impregnated fiberboard or expansion joint of claim
3, wherein the asphalt is a powdered asphalt.
16. The bitumen-impregnated fiberboard or expansion joint of claim
3, wherein the asphalt is a natural asphalt.
17. The bitumen-impregnated fiberboard or expansion joint of claim
3, wherein the asphalt is a synthetic or non-natural asphalt.
18. The bitumen-impregnated fiberboard or expansion joint of claim
3, wherein the asphalt is an emulsified asphalt.
19. The bitumen-impregnated fiberboard or expansion joint of claim
2, wherein the dye is a water-based dye having a pH of about 4 to
about 10 or a solvent-based dye having a pH of about 4 to about 10.
Description
RELATED APPLICATIONS
[0001] This application claims priority to, and is a continuation
of, co-pending U.S. application Ser. No. 13/772,931, having a
filing date of Feb. 21, 2013, which is a continuation of U.S.
application Ser. No. 13/526,177, having a filing date of Jun. 18,
2012, now U.S. Pat. No. 8,382,951, which is a continuation of U.S.
application Ser. No. 13/248,758, having a filing date of Sep. 29,
2011, now U.S. Pat. No. 8,241,463, which is a continuation of U.S.
patent application Ser. No. 12/881,721, having a filing date of
Sep. 14, 2010, now U.S. Pat. No. 8,038,845, which is a divisional
of U.S. patent application Ser. No. 12/200,993, having a filing
date of Aug. 29, 2008, now U.S. Pat. No. 7,815,772, all of which
are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to a process for
manufacturing fiber expansion joints. In particular, the present
disclosure relates to a method for introducing fine particles of
bituminous material, such as asphalt, into a slurry fiber mixture
for formation into boards used in fiber expansion joint
applications. Although the term "asphalt" is used throughout the
present disclosure, it should be understood that any bituminous
material, including tars and pitches, may be employed and still
remain within the scope of the present disclosure.
[0003] Asphalt impregnated expansion joints are used in connection
with concrete structures to relieve stresses created by thermal
expansion and contraction of the concrete and prevent failure of
the concrete caused by changes in ambient temperature. Typical
applications for asphalt impregnated fiber expansion joints include
sidewalks, driveways, floor slabs, streets, highways, airport
runways, and similar applications. Because such concrete expansion
joints are installed in applications exposed to the weather, it is
desirable that water absorption be limited to prevent degradation
of the expansion joint. It is also desirable that concrete
expansion joints have strength and resiliency. Therefore, asphalt
impregnated fiberboard expansion joints are required to meet or
exceed the requirements of ASTM Standard Specification D
1751-04.
[0004] ASTM D 1751-04 requires that an expansion joint for concrete
paving and structural applications have specified material
characteristics, including that 35% weight of the finished
fiberboard shall be asphalt uniformly distributed throughout the
board. Additionally, the stress required to compress a test
specimen of a fiber expansion joint to 50% of its original
thickness must not be less than 100 psi nor greater than 750 psi.
When a fiber expansion joint is compressed to 50% of its original
thickness having three of its edges restrained, the amount of
extrusion of the free edge cannot exceed 0.25 inch. A fiber
expansion joint that has been compressed to 50% of its original
thickness must recover at least 70% of its thickness within 10
minutes after the applied load is released. A fiber expansion joint
must not have a density less than 19 lb./cu. ft. A fiber expansion
joint test specimen with four square-cut edges, when submerged
horizontally under 1 inch of water at 70 degrees F. may not absorb
more than 15 volume % in 24 hours for a nominal volume of 1/2 inch
and no more than 20 volume % for all other thicknesses.
[0005] Fiber expansion joints have been made by saturating
fiberboard in an asphalt/solvent solution, allowing the asphalt
solvent mixture to be absorbed into the fibers, and allowing the
solvent to evaporate. Fiber expansion joints have also been made by
adding solid asphalt particles into a slurry of fibers. The asphalt
particles are dispersed in the fiber slurry by mechanical mixing,
and the slurry is dewatered, pressed into a board and dried.
BRIEF SUMMARY OF THE INVENTION
[0006] The present disclosure relates to a process for
manufacturing fiberboard including the steps of preparing a fiber
slurry mixture by adding a material containing cellulose fibers to
water and agitating the fiber slurry mixture and transferring the
fiber slurry mixture to a spray chamber. Then a bituminous
material, such as asphalt, is heated to a temperature between 300
and 440 degrees F., wherein the bituminous material is in a liquid
state. The liquid bituminous material is atomized within the spray
chamber by mixing it with a pressurized gas, such as compressed
air, forming a mist comprising droplets of bituminous material
having a diameter between 20 microns and 50 microns. A water spray
solidifies the bituminous material droplets thereby forming
bituminous particles which fall into the fiber slurry within the
spray chamber. From there the slurry is sheared, dewatered, and
dried, forming a finished fiberboard.
[0007] The present disclosure also relates to a process for
atomizing a bituminous material, such as asphalt, to produce solid
particles ranging in size from 20 microns to 50 microns. A
bituminous material is heated to a temperature between 300 and 450
degrees F., wherein the bituminous material is in a liquid state.
The liquid bituminous material is atomized by mixing the liquid
bituminous material with a gas, such as compressed air, by passing
each through a nozzle. The gas is supplied at a pressure between 10
psi and 50 psi, but preferably between 20 psi and 40 psi and a
temperature between 200 degrees F. and 300 degrees F. Mixing the
liquid bituminous material and the compressed gas produces a mist
of bituminous droplets having a diameter between 20 microns and 50
microns. A water spray having a temperature between 40 degrees F.
and 60 degrees F., but preferably between 45 degrees F. and 55
degrees F. is applied to the bituminous mist, solidifying the
bituminous material droplets and thereby forming bituminous
particles having a diameter between 20 microns and 50 microns.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0008] The present disclosure will be described hereafter with
reference to the attached drawings which are given as a
non-limiting example only, in which:
[0009] FIG. 1 is a schematic representation of the process of the
present disclosure;
[0010] FIG. 2 is a schematic representation of the spray tank of
the present disclosure;
[0011] FIG. 3 is a section view of an asphalt spray nozzle;
[0012] FIG. 4 is an end view of the nozzle shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The process for manufacturing an asphalt-impregnated
fiberboard of the present disclosure introduces fine asphalt
particles into a fiber slurry by atomizing molten asphalt and spray
cooling the atomized asphalt. The asphalt particles may then be
added directly to the fiber slurry or stored for later use.
[0014] Referring now to FIG. 1, a fiber slurry is prepared in a
pulper 10 by adding material containing cellulose fibers, such as
wood pulp, sugar cane, switch grass, straw, recycled paper pulp, or
other cellulose containing organic material to water. A mixer 12,
agitates the fiber slurry, maintaining the fibers in suspension.
The fiber slurry is transferred to a pulp chest 14 where it is held
while awaiting further processing, depending on production
parameters. Depending on the application, a pump 16 may be used to
transfer the fiber slurry from the pulper 10 to the pulp chest 14.
Alternatively, the fiber slurry may be transferred by gravity into
the pulp chest 14.
[0015] Asphalt is heated in a tank 20 to a temperature between 300
and 440 degrees F. At this temperature, the asphalt is in a liquid
phase and flows freely. From the tank 20, a pump 22 transfers the
molten asphalt through a filter to remove any impurities such as
solids or coking that may have formed during the heating process. A
heater 26 is provided to further heat the molten asphalt to a
temperature between 400 and 450 degrees F. The heater 26 also
provides heat to the piping carrying the molten asphalt to the
spray chamber 30.
[0016] In an exemplary embodiment, the heater 26 is a shell and
tube heat exchanger having hot mineral oil on the shell side and
the molten asphalt on the tube side. The heater maintains mineral
oil at a temperature of approximately 600 degrees F. The mineral
oil is circulated within the shell side of the heater, transferring
heat to the molten asphalt as it passes through the tube side of
the heater. The asphalt transfer piping 28 is constructed of double
lumen pipe, wherein the heated oil circulates through an outer
lumen to maintain the temperature of the molten asphalt as it is
flows through an inner lumen as it is transferred from the asphalt
tank to the spray chamber.
[0017] Referring now to FIG. 2, the spray chamber 30 includes a
housing 32, enclosing an atomization head 34. The atomization head
34 includes a plurality of asphalt nozzles 36. Each nozzle is
connected to the asphalt piping 28. In an exemplary embodiment, a
pump 38 is connected in-line with each nozzle 36 for metering the
flow of asphalt. Each nozzle 36 is also connected to a pressurized
air manifold 40.
[0018] An air compressor, 42 supplies a source of compressed air
which is dried and heated to a temperature between 200 degrees F.
and 300 degrees F. The dried compressed air is provided to each
nozzle 36 through a solenoid valve 44. The solenoid valve 44 allows
the compressed air to be applied to only those nozzles 36 in use
providing bitumen to the slurry in the spray chamber 30. The
compressed air may be provided at a pressure between 10 psi and 50
psi. In an exemplary embodiment, the compressed air is provided at
a pressure of between approximately 20 psi and 40 psi. It has been
found that moist air causes the molten asphalt to solidify
prematurely, resulting in clogging of the nozzles. It is therefore
desirable that the compressed air be passed through a suitable
commercially available air dryer before it is introduced into the
process.
[0019] Referring to FIGS. 3 and 4, each nozzle 36 includes a body
46 having a liquid passage 48, through which molten asphalt flows,
surrounded by a plurality of gas passages 50, which provide
pressurized air as shown in FIGS. 3 and 4. The liquid passage 48
and the gas passages 50 discharge into an atomization chamber 52.
The liquid passage 48 may be located along the longitudinal axis of
the nozzle body 46 and gas passages 50 symmetrically disposed about
liquid passage 48. Such a nozzle design is shown in U.S. Pat. No.
6,997,405 which is herein incorporated by reference. The
atomization chamber 52 is configured to combine the molten asphalt
and the pressurized air to produce an asphalt mist 54. The
atomization chamber 52 includes a conical wall 53 having an angle
.phi. which may be varied depending on the desired atomization
pattern. In an exemplary embodiment of the present disclosure, the
atomization chamber 54 has a wall angle .phi. of 45 degrees, which
produces a conical spray pattern having a vertex angle of 45
degrees. The atomized asphalt mist 54 is discharged from
atomization chamber 54 as liquid asphalt droplets having a diameter
of approximately 20 to 50 microns. The size of the asphalt droplets
may be varied by adjusting the air pressure. Generally, higher air
pressure produces atomized asphalt having a smaller particle
size.
[0020] The spray chamber 30 shown in FIG. 2 depicts five spray
nozzles for clarity. However, in an exemplary embodiment of the
present disclosure, the spray chamber 30 includes a spray head 34
having twelve spray nozzles 36. Each spray nozzle is designed for
an asphalt flow rate of 1 gal/min. Having solenoid valves
controlling the asphalt flow to individual nozzles allows for
varying the asphalt flow rate depending on the desired production
rate and/or asphalt concentration for the finished product. For
example, the amount of asphalt added to the fiber slurry may be
adjusted from about 1 gal/min, with a single solenoid valve open at
a minimum production rate to about 12 gal/min at high production
rates. Also, the number of nozzles in operation may be driven as a
function of the desired asphalt content in a finished product.
[0021] The spray chamber 30 also includes a plurality of water
spray heads 56 arranged proximate to the discharge of the asphalt
nozzles 36. The water spray heads 56 are connected to a supply of
chilled water maintained at a temperature of approximately 40
degrees F. to 60 degrees F. In an exemplary embodiment of the
present disclosure, the chilled water is provided at a temperature
between 45 degrees F. and 55 degrees F. The spray heads 56 are
configured to direct a water mist towards the atomized asphalt
discharge at a spray angle .theta. of approximately 45 degrees
downward. The chilled water mist solidifies the molten droplets of
the atomized asphalt mist, forming solid asphalt particles having a
size of 20 to 50 microns.
[0022] A pulp supply line 58 connects the pulp chest 14 to the
spray chamber 30. A slurry feed pump 60 is provided in the pulp
supply line 58 to transfer the fibrous material slurry from the
pulp chest 14 to the spray chamber 30. The slurry feed pump 60 may
be of variable speed and connected to a control system (not shown)
to accommodate variable production throughput.
[0023] The fibrous material slurry is pumped into the spray chamber
30 to a predetermined level 62. As the molten asphalt mist 54 is
cooled and the asphalt droplets solidify, fine asphalt particles
drop into the fibrous material slurry in the bottom of the spray
chamber 30. One or more mechanical mixers 64 agitate the fibrous
material slurry, maintaining a homogeneous mixture of fibers and
asphalt particles.
[0024] The slurry in the spray chamber 30 should contain about 8%
weight to about 10% weight fiber or solid content. The slurry
should also contain about 10% weight to about 30% weight
asphalt.
[0025] A discharge pump 66 is connected to the outlet of the spray
chamber 30 and directs the slurry to the next step in the process.
The discharge pump 66 may be coordinated with the fibrous slurry
feed pump 60 to maintain a predetermined slurry level and dwell
time within the spray chamber 30.
[0026] From the spray chamber 30, the slurry is transferred to a
refiner 68 where the slurry is sheared by a series of mixing
plates. The mixing plates are mounted on a shaft and rotate
relative to each other. As the slurry flows through the refiner, it
passes between the mixing plates, shearing the slurry and in the
process shredding the fibrous material. The shredding of the
cellulose fibers forms a large amount of surface area for
interaction with and dispersion of the asphalt particles, allowing
for even distribution of the asphalt particles throughout the
fibers.
[0027] Additional ingredients may be added to the slurry including
waxes, starches, alum, and other fillers and agents. These
additional ingredients and fillers may be added at any point in the
process prior to dewatering where they will become intermixed with
the other components, as is known in the art. For example a wax,
such as paraffin, may be added to the slurry in a concentration of
about 1.0% weight to about 2.5% weight; starch may be added in a
concentration of about in a concentration of about 1.0% weight to
about 3.0% weight; and aluminum sulfate may be added in a
concentration of about 1.0% weight to about 2.0% weight.
[0028] In an alternative embodiment of the present disclosure, a
dye may be added to the slurry before drying. The dye serves to
color the fibrous material to produce an evenly colored finished
fiberboard improving the aesthetic appearance of the fiberboard.
The addition of a dye, also serves to regulate the pH of the
slurry. The dye should have a pH of about 6 to about 8. It has been
discovered that a slurry having a pH of approximately 6.8 has been
found to promote better adhesion of the asphalt particles to the
cellulose fibers, and thus improved distribution of asphalt
throughout the finished fiberboard. The dye may be a generally
commercially available water-based dye. Alternatively, a solvent
based dye may be used. However, a solvent-based dye contains
volatile compounds which may be harmful to the environment and
which may present the risk of fire or explosion when subjected to
heat while drying.
[0029] A slurry transfer pump 70 pumps the slurry mixture from the
refiner 68 to a ready chest 72 where it is held for dewatering.
Another transfer pump 74 pumps the slurry from the ready chest 72
to a Fourdrinier-type press 76 as is commonly known in the art,
where the slurry is dewatered and formed into a wet fiber mat.
[0030] After the dewatered wet mat leaves the Fourdrinier press 76,
the mat passes through a shear 78 where it is cut before being fed
into a dryer 80. The mat is dried for approximately 1-3 hours
depending on its physical characteristics. The finished fiberboard
preferably should have about 10% weight to about 40% weight total
asphalt content and less than about 3% total moisture content.
After being dried, the fiberboard may pass through a second shear
82 again be cut to a commercially desirable size. The finished
fiberboard may then be stacked 84 for further processing or for
shipment.
[0031] Alternatively, an additional coating of asphalt or other
petroleum fluid may be applied to the outer surface of the
fiberboard to provide additional resistance to moisture
penetration. A coater 86 applies by roller the additional coating
to the major surfaces of the fiberboard. For example, a
commercially available hot melt double-sided roller coater
manufactured by the Black Bros. Co. may be used. Fluids such as
flux oil or fuel oil, in addition to asphalt, have been found to
resist water penetration into the finished fiberboard.
[0032] Although ASTM D 1751-04 specifies that the finished fiber
board have an asphalt content of at least 35.0% weight, a number of
tests were preformed on fiber boards manufactured by the process of
the present disclosure, varying the % weight of asphalt. For
example, an asphalt-impregnated fiberboard manufactured by the
process of the present disclosure containing 15% weight asphalt was
tested according to ASTM Method D 545. The results are summarized
in Table 1 below:
TABLE-US-00001 TABLE 1 asphalt content 15% weight Property Test
Results ASTM 1751-04 Compression (psi) 150 Pass Extrusion (in.)
0.30 Fail Recovery (%) 65 Fail Density (lb./cu. Ft.) 20 Pass Water
absorption 24 Fail
[0033] A second test was performed on a fiberboard containing 25%
weight asphalt content. The results are summarized in Table 2
below:
TABLE-US-00002 TABLE 2 asphalt content 25% weight Property Test
Results ASTM 1751-04 Compression (psi) 350 Pass Extrusion (in.)
0.25 Pass Recovery (%) 75 Pass Density (lb./cu. Ft.) 21 Pass Water
absorption (volume %) 19 Fail
[0034] A third test was performed on a fiberboard containing 35%
weight asphalt content. The results are summarized in Table 3
below:
TABLE-US-00003 TABLE 3 asphalt content 35% weight Property Test
Results ASTM 1751-04 Compression (psi) 540 Pass Extrusion (in.)
0.15 Pass Recovery (%) 78 Pass Density (lb./cu. Ft.) 22 Pass Water
absorption (volume %) 12 Pass
[0035] The process of the present disclosure allows introduction of
very fine asphalt particles into the fibrous slurry mix. It has
been discovered that small asphalt particle size allows for better
dispersion of the asphalt throughout the fibers and increased
bonding between asphalt and fiber. Thus a fiberboard may be
produced exhibiting improved characteristics over
asphalt-impregnated fiberboards produced by methods presently known
in the art.
[0036] While this disclosure has been described as having exemplary
embodiments, this application is intended to cover any variations,
uses, or adaptations using the general principles set forth herein.
It is envisioned that those skilled in the art may devise various
modifications and equivalents without departing from the spirit and
scope of the disclosure as recited in the following claims.
Further, this application is intended to cover such departures from
the present disclosure as come within the known or customary
practice within the art to which it pertains.
* * * * *